Custom Drive Shaft, Possibly Carbon Fiber

[autobahn terror]

Hello All,

Im sure most are already aware of the Drive Shaft Failure I had last Sat. If not, Check out the Catistrophic Driveshaft Failure Thread for details/Photos.

Any-Who, I have been hunting down some alternatives to the stock 2 Piece Carrier Bearing Shaft that is basiclly a base F150 Shaft that was mad to work in a AWD Taurus and other similar AWD Platforms. Im am unsure of Placement of this thread, but since I am getting this done for a SHO ill put it here for now...

It took about a week of internet hunting and calling custom shops, but I finally found one who will be takeing possesion of my old CV joints to look at fesability of a custom shaft, most likely made from Carbon Fiber. This would be a Huge upgrade for guys who like to go fast, as the F150 base shaft is notoriously junk, and unable to be repaired even if the failure is not as bad as mine was.

There was another shop I found that stocks OEM style Shafts that are steel, but with slighty thicker walls and larger tube diamater. Not enough to be ground breaking and it costs the same as a stock Shaft, so it may as well be.

Personally, I want to go FAST. and I dont want to destroy the car or my life doing it. SO...I am looking to find out how many people in the community are interested in a group buy of Carbon Fiber Shafts, or even interest to convice the driveshaftshop to offer a CF shaft made to fit the SHO/FLEX/platform as they do already for the mustang. www.driveshaftshop.com

I need to know soon However, as this process is already in motion, and customer base will determine the shops willingness to put effort into product development.

 

[Gjkrisa]

I would LOVE to but I'm waiting another year at least before ruining my warranty but also of I can get ford to say these are an upgrade I need to pay off credit cards first.

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[irondoor19]

FOR ME,AS always there is an interest, BUT it
also goes back to HOW MUCH (approx) are we talking,
and as the MODS are ever increasing, the budget is getting smaller

 

[autobahn terror]

Anybody have access to a lift or the time to get some full length pictures of the stock driveshaft installed on their SHO? need the pics for the custom shaft build and for obvious reasons, i dont have a drive shaft to take pictures of myself...

 

[ZSHO]

That's all i have for now brother but will try to get some more pics later for ya.  Z

 

[Gjkrisa]

This is what I have https://goo.gl/photos/2CJSx8VcWWq84kvd9

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[irondoor19]

Taking Pics of the Shaft as we Speak, AND ON ANOTHER NOTE

SO went to the Ford  dealer Nearest ME (not my favorite Dealer)
and
asked about a price for the Drive shaft carrier bearing...
Instead they told me you have to buy the whole assembly 764.64 List
yea Right, anyone that has a good Dealer that might be able
to break this down.. Would appreciate it a whole bunch....

HEY: PICKED UP A USED DRIVE SHAFT from 2011 w 20K Miles Complete for 130.00

Down side of taking the attached pics.. if you want entire length pics
the exhaust has to be removed. and that is not happening any time soon

 

[SHOdded]

Yup pretty standard to replace the entire driveshaft.  Not to say you couldn't do some measurements, call up some bearing mfrs and custom build one yourself.

 

[irondoor19]

Ok lets try this again, i went out and looked, made him take these pics again..

 

[autobahn terror]

I highly appreciate all the pictures and help from you guys. Here is the latest. The DriveshaftShop is requiring an OEM shaft and Carrier support structure in order to Complete a CF custom shaft.

irondoor19... Where did you see that used shaft for 130? I requested a quote from the dealership nearest to the DriveShaftShop in NC, but I am expecting a $800 bill just to provide an example shaft.

I need to see if there are any differences between the 2012/below and 2013+ years.

Can I get another Head Count on people who are interested in purchasing the newly developed CF shaft?

 

[autobahn terror]

Can I get another Head Count on people who are interested in purchasing the newly developed CF shaft?

Looks like the carbon fiber shaft is a go. The drive shaft shop quoted me 1650 for a 3.8 inch diameter shaft. says the first one is discounted because it needs to test fit with plates. i am going to send im my ends from the failed shaft. Is anyone near NC that is looking for a CF shaft for their Sho? i dont mind doing the test fit, just think it would go alot smoother with someone in the states closer to the shop.

 

[shaundizzle15]

Did this ever fully come to life? Just curious

 

[SHOdded]

I would PM him directly.

 

[autobahn terror]

Hey Shaundizzle,

Yes It is in the works, its been a while but I had to wait alittle due to the racing season and such.

The last word i got was I am in line at the CNC mill for the custom adapter plate fabrication.

The Group buy thing never went anywhere because everyone wants to see what mine ends up looking like and performing like first i guess. I am also looking into the half shafts up front for safety, as I have been driving the car FWD since the problem, and I havnt been nice about it.

I havnt been getting notifications so I will be looking at the forum more often now...

 

[SHOdded]

I think the notification settings were too tightly set, and I have updated your profile to allow more latitude.  Let's see if it works!

Glad to see the project is still progressing.  Did you see the other thread where they basically converted the car to FWD fulltime?
https://www.ecoboostperformanceforum.com/index.php/topic,8539.msg128652.html#msg128652

 

[autobahn terror]

Ok, DSS has informed me the mounting plates for the shaft are about done. They will be spinning the shaft soon and shipping ASAP. They had a bunch of none related issues that slowed this whole thing down but the time is now fast approaching.

Who is looking to get in on a group purchase?

 

[SHOdded]

Let's get a head count, folks!  Make this happen!

 

[bpd1151]

Who is looking to get in on a group purchase?

Oh snap! Nice work and what a fantastic update!

I can place a deposit down, that's about it for now.

No effing way in hell I'm coming up w/the full amount before Christmas.

No way.

Middle or end of January I can pay remaining balance.

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[StealBlueSHO]

Are we still taking $1,650?

 

[autobahn terror]

Hello Folks,

Sorry for the long delay. Here is the latest news. I was in contact with Drive shaft shop and working with them to create one piece replacemet shaft. The final dimensions to make it safe came to be too large to fit in the tunnel. When I approched them about modifing the plan to make the shaft a 2 piece upgrade instead, they cut off communications with me. I am currently talking with Kerbid, the makers of the VooDooChikin Polyurethane Carrier Bearing for the CTS-V. I purchased a used Shaft off of ebay and sent it to them so they can develop a product for the SHO. After speaking with them they same the stock shaft while not ideal, is still plenty strong and could benift from the Bearing upgrade. While it wont let me hit my goal of 300KPH on the autobahn, it will enable a long life of dig racing and hard driving for the rest of you.

Remeber that the JTEK setup in the SHO, and all D3's probably is Front wheel Drive biased, that is, that the rear wheels dont put down most of the power, they just help out when the fronts slip. As such, the shaft dosent see as much torqe applied as a normal RWD car does, but it does continually spin at the rate of speed the car is traveling. This makes the poly bearing even more attractive in my mind.

Let me know what you all think. I dont have a completion time for a test part yet, (the OEM method for attaching the Stock Bearing is molding), once they figure out if they can do it ill let everyone know. Feel free to PM me if you want to know more of the dirty details...